Composite material and method of producing same



Oct. 24, 1939. J. P. BURKE 2,177,092

'COMPOSITE MATERIAL AND METHOD 0F PRODUCING SAME Filed April 12, 1937 ATTORNEYS Patented Oct. 24, 1939 UNITED STATES i PATENT OFFICE ali-7,092

COMPOSITE MATERIAL AND METHOD OF PRODUCING SAME James P. Burke, Knoxville, Tenn., assignor, by mesne assignments, to Vermiculite Corporation of America, Detroit, Mich., a corporation of Michigan Application April 12, 1937, Serial No. 136,457 3 Claims. (Cl. 91-68) The invention relates to composite materials containers through a conduit G and branch conof that type including vermiculite or equivalent duits H, I and J. Valves K, L, and M in the siliceous material and a binder. It is one of the conduits H, I and J may be adjusted to regulate objects of the invention to apply a composition the pressures in the separate compartments, and.

5 of this type to a fabric base to form thereof a valves or dampers N and O in the conduits D material suitable for use as a iioor covering and and E regulate the feed of the vermiculite and other analogous uses. It is a further object to binder into the container F. Within the conform a material of this character employing a tainer F is a mechanical agitator P which is of varnish binder for the vermiculite, and still fursuch a nature as to vnot only stir and commingle l ther it is an object to simplify and expedite the the vermiculite and binder, but also to intro- 10 process of manufacture. With these objectsin duce into the mixture a quantity of air. As a view, the invention consists in the composite maresult the material discharged from the lower terial and method of forming the same as hereend of the container F has a relatively high perinafter set forth. centage of voids or air passages, there being only i In the drawing: sulcient binder to cement the vermiculite parl5 Figure 1 is a vertical longitudinal section of ticles to each other without lling these voids. an apparatus suitable for producing my improved The Vdischarge conduit Q from the chamber F has composite material; a regulating valve R and also a telescopic nozzle Figure 2 is an enlarged view illustrating the S which may be raised or lowered and has a x successive steps in the manufacture of the same. discharge S1012 S extending transversely aCIOSS 20 The principal ingredient of my improved the fabric fed from the roll A. This fabric is composite material is exfoliated vermiculite which supported on a shelf or table T and by adjusting is formed by subjecting natural vermiculite to a the nozzle S in relation thereto the depth of heat treatment. This disintegrates the natural material deposited on the fabric may be regu' .5 material forming thereof relatively small flakes lated. From the table T the fabric passes which are so twisted or curled as to form air through an ovenUheated by any suitable means, pockets therebetween and to greatly increase the preferably i a temperature from 130 F- t0 375 bulk. 'I'he separate particles are integrated by F. It then passes out of the oven to feed rolls a suitable binder of the nature of Varnishor a V which not Only form the advancing means but 0 resinous material. It is, however, desirable to also crush down the porous mass to ascertain 30 limit the quantity of the binder so as to leave the extent. The material is further compressed and voidsbetween particles unlled and in more or dnsied in a press W, the platens W and W2 less communication with the external atmosof which are heated to a temperature from 180 phere. As a consequence, the varnish lms will F. to 375 F. The operation of this Dress is quickly dry particularly if subjected to heat. intermittent while the feeding of the fabric The material as thus far described, forms the past the nozzle S and through the oven U and Subject matter of a co-pending application Serial rolls V is constant. Therefore, thematerial upon No. 136,456, led April 12, 1937, for patent and leaving the rolls V falls in a loop X while the is useful for various purposes, such as thermal advanced portion is in the 'press and this will and sound insulation. If, however, it is desired supply suflicient material for a succeeding press- 40 to use the material as a floor covering or for ing operation. other purposes where it iS subjected G0 Wear. it The process of manufacture as above described 1s necessary that it should be densied which has the important advantage that the porous may be accomphshed by Sub-lectmg the Same t0' material first deposited upon the fabric may be pressure. Also, the material must be applied quickly Cured or dried by reason of communicato some suitable fabric which will impart thereto the necessary tensile strength. tion between the 1nter1or a1r cells and the ex- Fi r 1 ternal atmosphere. On the other hand, if the w lap or other suitable fabric for forming the base of ed form 1t would I equne a long pellod of time 50 the material. Band C are containers respectively to harden'the. Varmsh bmder Denslfyng after for the exfoliated vermiculite andl the binder and the drying of the binder is easily performed par" which are connected through onduits D and E ticularly where the platens of the press are heatwith a mixing chamber F, Air under pressure ed to a temperature at which the binder becomes 5 is introduced into the upper end of each of these adhesive. Sticking of the material to the rolls 455 and piatens or the press is prevented by coating the same with beeswax o1' other suitable lubricant.

What I claim as my invention is:

l. As an article of manufacture, a fabric base and a layer of a, substantially densified composition of exfoliated vermiculite, and a varnish binder applied to said base having an exposed surface.

2. As an article of manufacture, a burlap strip and a substantially densiiied composition of exfoliated vermuculte, and a varnish binder iin-n arranca pregnating said buriap strip forming an outer coating therefor having an exposed surface.

3. A method of forming iioor coverings comprising, oommingling exfoliated vermiculite and a limited quantity of varnish binder, introducing air into the mixture forming thereof a porous mass, depositing the mixture in the form of a sheet on a fabric base permitting the varnish binder to dry and then applying suilicient pressure to form a. densied layer of the mixture on l0 said fabric base.

JANIES P. BURKE. 

